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Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns
Fe b rua ry 2, 20 17 Slid e 2
This is ABB
”Power and p ro d uct ivit y fo r a b e t t e r wo rld ”
Fe b rua ry 2, 20 17 Slid e 3
Corporat e Research Cent ers
Väst erås SE
Ladenburg DE Krakow PL
Baden CH
Windsor US Beijing CN
Raleigh US
Shanghai CN
Bangalore IN
Materials DECRC
Mechanics
INCRC
Xiaolong Feng
Akilur Rahman
Power electronics
Georgios Demetriades PLCRC
Marek Florkowski
Sensors
Barbara Panella
SECRC
Sof t ware Mikael Dahlgren
Roland Weiss
USCRC
Switching
Le Tang
Riccardo Bini
Fe b rua ry 2, 20 17 Slid e 5
Out line
Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns
Fe b rua ry 2, 20 17 Slid e 6
What can we expect f rom t he f ut ure?
Distribution
Customers
s up p lie r
Sales
Sub -
s up p lie r
Production
Sub -
s up p lie r
R&D Q, IT, etc
Pa rt ne r Pa rt ne r Pa rt ne r
Fe b rua ry 2, 20 17 Slid e 8
Market Trends
The Five Major Trends t hat Manuf act urers Must Follow
Int e rne t
What the industry really needs
of
Thing s
Lo we r co s t Be t t e r Big Mo re
a nd Pro d uct io n asset
MoSa fe t yy
b ilit s im p lifie d e fficie ncy ut ilit iza t io n Daetffe
a ct ive
d e cis io ns
o p e ra t io ns / ROA
The hyp e
Clo ud
Ana lyt ics Co m p ut ing
Fe b rua ry 2, 20 17 Slid e 9
Today’s aut omat ion syst ems
Aut omat ion Net work and Hierarchy
ERP
(Level 4)
MES / CPM
(Level 3)
Supervisory control
(Level 2)
Regulatory control
(Level 1)
Process
(Level 0)
Fe b rua ry 2, 20 17 Slid e 10
Today’s Product ion Syst em Workf low
Several Hierarchical Decision Layers – To p Do wn
De m a nd s , co s t s
Pla nning Op t im iza t io n!
Pro d uct io n t a rg e t s Pro d uce d a m o unt s
Fe b rua ry 2, 20 17 Slid e 11
What is happening next ?
Upper levels moving t o t he cloud
ERP
(Level 4)
MES / CPM
(Level 3)
Supervisory control
(Level 2)
Regulatory control
(Level 1)
Process
(Level 0)
On-s it e clo ud
Glo b a l clo ud
p la t fo rm
Fire wa ll
Re a l-t im e b us
De vice s
Fe b rua ry 2, 20 17 Slid e 13
OPTIMAX® PowerFit
Opt imizing cont rol of Virt ual Power Pools
Ta s k
• Ag g re g a t e m a ny s m a ll p ro d uct io n unit s a nd
t re a t t he m like o ne b ig p o we r p la nt
• Exp lo it m ult ip le fo rm s o f e ne rg y (e .g . e l a nd
he a t ) a nd s t o ra g e s
So lut io n
• Build o ve ra ll p la nt m o d e l (e xp lo it ing
Mo d e lica m ult i-p hys ics )
• Fo rm ula t e o p t im izing co nt ro l t a s k a s
m a t he m a t ica l p ro g ra m
• Online o p t im iza t io n o f s e t p o int s a nd p la nt
s che d ule s
Dig it a liza t io n e na b le s t he int e rco nne ct io n o f p o we r g e ne ra t io n, co ns um p t io n, s t o ra g e a nd
p ro d uct io n
Fe b rua ry 2, 20 17 Slid e 14
Out line
Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns
Fe b rua ry 2, 20 17 Slid e 15
Model predict ive cont rol: advancing t he f ront iers
lndust ry re q uire m e nt s vs a va ila b le p ro ce s s ing p o we r
Po we r Ge ne ra t io n
Ele ct rica l
Ce m e nt & Mine ra ls
Pulp & Pa p e r
Ro lling Mills
Re fining
Che m ica ls
Fe b rua ry 2, 20 17 Slid e 16
Case st udy : Mondi Swiecie, Poland
Digest er APC Overview
Op e ra t o r o ve rvie w
APC d is p la y
Fa ce p la t e s
Swit ch APC a nd
Sup e rvis o ry m o d e
Fe b rua ry 2, 20 17 Slid e 17
Case st udy : Mondi Swiecie, Poland
Mid-p o int Ka p p a co nt ro l: Re s ult s b e fo re & a ft e r APC im p le m e nt a t io n
Fe b rua ry 2, 20 17 Slid e 18
DeepMind AI f or Dat a Cent er Cooling
Reduces Google Dat a Cent re Cooling Bill by 40%
Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
Eng ine e ring Efficie ncy
Co nclus io ns
Fe b rua ry 2, 20 17 Slid e 20
End of Isolat ed Solut ions
Balancing Bet ween Cont rol Syst ems
Production Management
(P&S, APC, Analytics, …)
© ABB Group
February 2, 2017 | Slide 21
Indust rial demand side management in pulp & paper
Coordinat ion of product ion planning and energy management
t1
t6
t11
t16
t21
t26
t31
t36
t41
t46
t51
t56
t61
t66
t71
t76
t81
t86
t91
t96
t101
t106
t111
t116
t121
t126
t131
t136
t141
t146
t151
t156
t161
t166
Pa p e r o ut p ut o f p la nt is not
reduced Time [hours]
Reduced pulp
production Running Ta s ks wit h iDSM
4
2
0
t11
t16
t21
t26
t31
t36
t41
t46
t51
t56
t61
t66
t71
t76
t81
t86
t91
t96
t1
t6
t101
t106
t111
t116
t121
t126
t131
t136
t141
t146
t151
t156
t161
t166
Fe b rua ry 2, 20 17 Slid e 22 Shift ing p ro d uct io n t o lo w co s t t im e s
Indust rial demand side management in pulp & paper
Evaluat ing market opport unit ies f or t he rm o m e cha nica l p ulp ing (TMP) m ills
[€ / MWh]
0 S1 24 6%
t17
t25
t33
t41
t49
t57
t65
t73
t81
t89
t97
t1
t9
t105
t113
t121
t129
t137
t145
t153
t161
Energy Allowed pulp S2 26 5%
Scenario
cost st orage levels Tim e [ho urs ]
S0 No 20 %-80 %
Sp o t Ma rke t Ho urly Price s (1s t we e k,
S1 Ye s 20 %-80 % No. of
De ce m b e r 20 14) Savings
st art s
S2 Ye s 5%-95%
100
Ele ct ricit y Price
50 S0 7 0%
[€ / MWh]
0 S1 34 4%
t17
t25
t33
t41
t49
t57
t65
t73
t81
t89
t97
t1
t9
t105
t113
t121
t129
t137
t145
t153
t161
S2 33 4%
Tim e [ho urs ]
Fe b rua ry 2, 20 17 Slid e 23
NMPC f or Load Commut at ed Invert ers
Cont rolling 48 MW at 1kHz s a m p ling ra t e
LCIs p la y a n im p o rt a nt ro le in
Goal p o we ring e le ct rica lly-d rive n
co m p re s s o r s t a t io ns . Ena b le LCIs
t o rid e t hro ug h p a rt ia l lo s s o f g rid
vo lt a g e .
Fe b rua ry 2, 20 17 Slid e 24
Out line
Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in – Mining a s e xa m p le ca s e
The m o d e lling co m p le xit y
Co nclus io ns
Fe b rua ry 2, 20 17 Slid e 25
Mining value chain
Mine - Pro ce s s ing - Po rt
Mine
Po rt
Pro ce s s ing
• Bo lid e n s t a t e d t ha t t he p ro je ct
is im p o s s ib le !
• MPC + s t a t ic no nline a r
o p t im iza t io n
• Op t im ize fina ncia l o ut p ut
b a s e d o n d yna m ic p rice
m o d e ls
• Incre a s e d t hro ug hp ut b y 1-2
p e rce nt unit s
Fe b rua ry 2, 20 17 Slid e 27
Underground mine product ion
Blast cycle e xp a nd s t he m ine
Source: 1 A pragmat ic
approach t o mine
aut omat ion, ABB Mining
Conf erence Cape Town,
More t han 50 operat ions in a harsh and high risk 2013
In reach is a signif icant product ion increase of 40-50% t hrough aut omat ion
Fe b rua ry 2, 20 17 Slide 28 *Source: Final report Zepa, SMIFU Work package 1, Rock Tech Cent re, 2011-12-15
Aut omat ed scheduling - MineInsight
Short t erm scheduling in closed loop
Scheduler
Execut or
Wo rk o rd e rs Pro g re s s o f wo rk
Mo nt hly p ro d uct io n p la n
Pe rs o ne ll a nd m a chine a va ila b ilit y
Ma chine cha ra ct e ris t ics a nd d is t a nce s
Vent ilat ion where needed Real-t ime f eedback cont rol
Fe b rua ry 2, 20 17 Slid e 30
ABB Mine Locat ion Int elligence™
Increased saf et y and product ivit y
Fe b rua ry 2, 20 17 Slid e 31
Out line
Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns
Fe b rua ry 2, 20 17 Slid e 32
Modelling vision – Aut omat ion of aut omat ion
Aut omat ically g e ne ra t e m o d e ls fo r co nt ro l a nd o p t im iza t io n fro m CAD
Process graphics in 800xA
Modelica model
CAD
Fe b rua ry 2, 20 17 Slid e 33
Virt ual commissioning
Commissioning us ing a (s im ula t e d ) virt ua l re a lit y
Fe b rua ry 2, 20 17 Slid e 34
Learning models f rom hist oric dat a
Finding int e rva ls t ha t a re us e ful fo r m o d e lling
• Me t ho d a va ila b le fo r s ys t e m
id e nt ifica t io n us ing inp ut -
o ut p ut d a t a
• Le s s t ha n 5 % o f no rm a l
o p e ra t ing d a t a us e ful fo r
id e nt ifica t io n
• Ca n (his t o ric) d a t a b e us e d
a ls o fo r a p p lica t io ns le a rning
d e cis io n m o d e ls ra t he r t ha n
p ro ce s s m o d e ls ? Fo r e xa m p le
• Ala rm m a na g e m e nt
• Pro d uct io n s che d uling
• Sup p ly-cha in o p t im iza t io n
Fe b rua ry 2, 20 17 Slid e 35
Out line
Fact s a b o ut ABB
Fut ure Aut o m a t io n
MPC s t ill t he wo rkho rs e ?
Int e g ra t io n o f p o we r a nd a ut o m a t io n
Mo ving up t he va lue cha in
The m o d e lling co m p le xit y
Co nclus io ns
Fe b rua ry 2, 20 17 Slid e 36
Conclusions
Digit alizat ion is Inevit able
We s e e s hift s fro m
Prio p rie t a ry t o o p e n a rchit e ct ure s
Mult iva ria b le co nt ro l wit h fe w in-o ut t o De e p MPC
Is o la t e d t o int e g ra t e d p o we r a nd a ut o m a t io n
s ys t e m s
Lo w le ve l co nt ro l t o o p t im iza t io n o f e nt ire va lue
cha in
Ma nua l t o a ut o m a t ic g e ne ra t io n o f m o d e ls
Re a l t o virt ua l co m m is s io ning
Fe b rua ry 2, 20 17 Slid e 37
Acknowledgement s
The aut hors are grat ef ul t o many co lle a g ue s , e s p e cia lly wit hin ABB, fo r d is cus s io ns a nd s lid e s .
Fe b rua ry 2, 20 17 Slid e 38